I'm beginning to wonder if I'm every going to get this project done!!!!!!!!!!
I started out this morning by calling my local NAPA Auto Parts Store, talked to Rusty and ordered the TV cable. He said they have one in Columbus, I can have it for you by about 1:30 or so...Excellent, get it here!
After I got back from dropping off my daughter at preschool, I decided to open up the transfer case and change the input shaft....what a PAIN IN THE A$$!!!
I must correct that, the job would not have been nearly as bad if I had a little warning or had known better than to do what the TM said. Let me explain...
The TM has you start by taking off a bunch of unnecessary stuff like the 4 wheel drive switch and the entire output bell. I skipped those parts for obvious reasons. But when it get's to the inside, since I've never had one of these apart before, I decided to play along and do what they suggest. WRONG. This is where the TM gets you into trouble. The TM says to remove the retaining rings from both the drive sprocket and driven sprocket so both can be lifted out to remove the chain..DO NOT DO THIS!!!! There is a nice little note under the illustrations that says "Roller bearings ( 58 ) may fall out of drive sprocket (55) when drive sprocket is removed. There are 120 roller bearings. Ensure that all are present".
This note needs to be changed from "bearings
may fall out" to "bearings
WILL fall out, and you will need to totally disassemble the rest of the case on the input side to get the bearings that fall down through the planetary and under the plate below the input shaft!" I find out after the fact that removing the retaining ring and drive sprocket is unnecessary because you can simply lift out the entire output shaft as an assembly, along with the driven sprocket to remove the chain. Needless to say, I had to use some hillbilly engineering to reassemble the bearings into the drive sprocket. But, I finally got the case put back together and mounted on the truck. I also installed my brandy new rear drive shaft!
While I was waiting for my wife to get back from picking up our daughter, going to the store and NAPA for me so I could get my new TV cable; I decided to start installing the oil cooler for the transmission. While it is a nice cooler kit, they don't provide enough hose in the kit for larger trucks like ours. I guess they do if you want the cooler to be off to the side of the radiator rather than in the center...I like mine in the center. So, as I'm finishing the cooler up as far as I can with the limited amount of hose they give you. My wife comes home with my new TV cable. Great, I can throw that bad boy on and be done with the drive line stuff...WRONG. It is the correct cable, but while I was clipping the end onto the TV bracket rod at the IP, the plastic end of the cable broke.
![Banging Head aua aua](https://www.steelsoldiers.com/images/smilies/icon_smile_banghead_125.gif)
. SO, back on the phone with NAPA. The are going to have another one for me first thing in the morning.
Also, while I was waiting on my wife, I removed the OEM fuel filter and installed the base for the one I am going to use. I'll need to swing by the hardware store tomorrow morning and get some barb fittings to hook up the fuel lines, then that one will be done.
Can someone tell me why there are 3 wire connectors on the OEM fuel filter? I know one is for the water in fuel light, but what are the other two for? Also, I plugged off the vacuum line going to the turbo 400 transmission, but what is the other vacuum line for. Coming off of the pump, there are 2 lines, one goes to the transmission, and the other goes to the back of the engine to what I have no idea (I know where it goes, but I haven't a clue what the part is it's hooked to)
I'll try to snap a pic of the TV cable differences later tonight before I take the broken one back to NAPA and send the wrong one back to Rockauto.com.